Modular Non-Methane Hydrocarbon Conversion for Hydrogen and Methane
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Solution Overview
Problem
Existing methods for processing associated gas from oil wells are energy-intensive, costly, and inefficient, leading to wasted energy and emissions, with high-value NGLs being unusable and requiring off-site transportation, while hydrogen production is uneconomical in remote settings due to scale and energy requirements.
Innovation Solution
A modular hydrocarbon conversion system that includes a heavy hydrocarbon reforming module and optional modules for carbon dioxide and synthetic natural gas production, allowing flexible output selection of hydrogen or methane-rich fuels, reducing energy consumption and on-site processing complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If mechanical refrigeration units or membrane systems are used to separate NGLs from associated gas, then a methane-rich gas stream is produced, but a high heating value NGL by-product stream is created that requires off-site transportation and processing
Solution Approach 1:
The patent extracts and converts the problematic NGL by-product stream into valuable hydrogen and synthetic natural gas products through catalytic reactions, eliminating the need for separate NGL transportation and processing infrastructure while maintaining methane-rich gas production
Solution Approach 2:
The patent changes the chemical composition parameters of the NGL stream by converting C2+ hydrocarbons into hydrogen and methane through controlled catalytic reactions, transforming a waste product into valuable fuel components
2Quantity of substance
If the entire associated gas stream is converted into liquid fuel through gas-to-liquid (GTL) processing, then fuel production is achieved, but the process is uneconomic at the scale needed for remote field applications
Solution Approach 1:
The patent segments the associated gas processing into two distinct product streams: a liquid fuel component (synthetic natural gas) and a gaseous component (hydrogen), allowing flexible scaling and economic optimization for remote field applications rather than requiring complete conversion to liquid fuel
Solution Approach 2:
The patent employs dynamic catalytic conversion processes that can adjust product distribution between hydrogen and synthetic natural gas based on market conditions and operational requirements, providing economic flexibility not available in fixed GTL processes
3Quantity of substance
If steam methane reforming is used to produce hydrogen from hydrocarbon streams, then hydrogen gas is generated, but the process requires large scale centralized plants due to energy intensity
Solution Approach 1:
The patent replaces the high-temperature steam methane reforming mechanical/thermal process with a catalytic conversion system operating at lower temperatures and pressures, enabling distributed small-scale hydrogen production in remote field locations without requiring large centralized plants
Solution Approach 2:
The patent changes the operating parameters from high-temperature steam reforming to lower-temperature catalytic conversion, fundamentally altering the energy intensity and scale requirements of hydrogen production to enable remote field applications
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system efficiently converts non-methane hydrocarbons into hydrogen and methane streams, providing flexible fuel options and reducing transportation and storage costs, while minimizing emissions and increasing energy utilization.
Implementation Method 1
a catalyst adapted to react at least a portion of non-methane hydrocarbons into carbon oxides and hydrogen via steam reformation
Implementation Method 2
a catalyst adapted to react at least a portion of carbon oxides and hydrogen into methane via methanation
Data Source
AI summary
The disclosure relates to methods, systems, and apparatus arranged and designed for converting non-methane hydrocarbon gases into multiple product gas streams including a predominately hydrogen gas stream and a predominately methane gas steam. Hydrocarbon gas streams are reformed, cracked, or converted into a synthesis gas stream and methane gas stream by receiving a volume of flare gas or other hydrocarbon liquid or gas feed, where the volume of hydrocarbon feed includes a volume of methane and a volume of nonmethane hydrocarbons. The hydrogen contained in the syngas may be separated into a pure hydrogen gas stream. A corresponding gas conversion system can include a super heater to provide a hydrocarbon feed/steam mixture, a heavy hydrocarbon reactor for synthesis gas formation, and a hydrogen separator to recover the hydrogen portion of the synthesis gas.